IR 05000261/1980010
| ML14175B171 | |
| Person / Time | |
|---|---|
| Site: | Robinson  |
| Issue date: | 07/11/1980 |
| From: | Foster L, Shafer W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML14175B170 | List: |
| References | |
| 50-261-80-10, NUDOCS 8008180181 | |
| Download: ML14175B171 (7) | |
Text
$ RCgy 0 5 UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTA ST., N.W., SUITE 3100 ATLANTA, GEORGIA 30303 Report No. 50-261/80-10 Licensee:
Carolina Power and Light Company 411 Fayetteville Street Raleigh, NC 27602 Facility Name:
H. B. Robinson 2 Docket No. 50-261 License No. DPR-23 Inspection at H. B. Robinson site near Hartsville, South Carolina Inspector:
Y.//
{
L. E. Foster, Inspection Specialist, PAB ate Signed Approved by:
-
s-W. D. Shafer, Acting Chief, Performance
" /Cate Signed Appraisal Branch SUMMARY Inspection Dates:
June 9-13, 1980 Areas Inspected Special announced Performance Appraisal Inspection of the licensee's program associated with the control of centrifugal pumps manufactured by Pacific Pump Division of Dresser Industrie Review of purchase orders, specifications and documents relating to the design, fabrication, testing operation and maintenance of these pump The inspection involved 32 inspector-hours on site by one Performance Appraisal Inspecto Results Of the area inspected, no items of noncompliance or deviations were identifie DETAILS Persons Contacted Licensee Employees
- R. B. Starkey, Jr., General Manager
- R. T. Connolly, Director, Nuclear Safety and QA
- B. W. Garrison, QA Supervisor
- M. B. Williams, Project QA Specialist
- L. N. Williams, Security Specialist S. B. Anderson, Document Control Aide D. Baur, Senior QA Specialist K. Dripps, Technical Aide, Administrative Department R. H. Chambers, Maintenance Supervisor H. L. Zimmerman, Manager, Technical and Administration B. Watkins, Administrative Supervisor J. Curley, Engineering Supervisor S. Crocker, Environmental and Radiation Control Supervisor G. Bell, QC Specialist
- Attended exit interview Exit Interview The inspection scope and findings were summarized on June 13, 1980 with those persons indicated in paragraph 1 abov During this exit interview, the inspector also presented the results (detailed in IE Report 80-12) of the Security Inspection performed by RII Inspectors, J. Vorse, and D. McGuir The licensee was informed that no items of noncompliance or deviations were identifie.
Licensee Action on Previous Inspection Findings The inspector did not review previous items of noncompliance or unresolved items on this inspectio.
Unresolved Items No unresolved items were identified during this inspectio.
General The Performance Appraisal Branch conducted an indepth review of the licensee' s program and performance associated with control of Safety Related Component The components selected for this series of Performance Appraisal inspections were the centrifugal pumps manufactured by Pacific Pumps Division of Dresser Industries. These pumps are used on several safety related systems such as the Charging, Safety Injection and Auxiliary Feedwater System The H. Robinson Plant utilizes these pumps in the Auxiliary Feedwater Syste The selection of centrifugal pumps was based on problems encountered with centrifugal pumps as described in NRC Information Notice No. 80-07, dated February 29, 1980, and failure rates reported in the "Nuclear Plant Relia bility Data System Report" (NPRD). Objective and Scope The objectives of these inspections are to verify that the component has been designed, fabricated, installed, tested, operated and maintained as required by applicable specifications; to verify that the licensee/vendor has and is implementing controls to ensure that the component fulfills its design objectives and functions; and to determine the effectiveness of the licensee's program associated with Safety Related Component The scope of the inspection included a review of purchase orders, specifica tions, drawings, vendor inspection reports, test results, trouble tickets, procedures, modification packages, and maintenance records associated with Pacific Pumps Serial Nos. 43570, 43571, 44096, 44097 and 44098. Interviews with licensee personnel were also hel.
Documents Reviewed (a) FSAR Section 10, Steam and Power Conversion System (b) Technical Specifications 3.4 and (c) CP&L Purchase Order No. 434107 and Supplements 1 through 7 (d) EBASCO Services, Incorporated Specification No. 49-46 dated 8/5/66 and Revisi~ons 1 and 2 (e) CP&L Specifications CPL-R2-M-4 and 5 (f) Pacific Pump Technical Manual No. 1200 (g) EBASCO Files on Materials Engineering, Quality Compliance, and Vendor Inspections (h) Correspondence between CP&L, EBASCO, Pacific Pumps and Westinghouse concerning design changes, spare parts, test data and technical manuals (i) Section No, 4, 5, 7, 8, 9, and 10 of Volume II of CP&L QA Manual (j )
CP&L QA Procedure No QAP 2, 3, 6, 7, and 8 (k) Trouble Tickets on Auxiliary Feedwater Pumps for 1979 and 1980 (File Folder Nos. 2-C-4c and d)
(1) Maintenance Instruction MI-10, Procedure No and 21 "Repair of Auxiliary Feedwater Pumps" (in)
Drawing Nos. C13925, D5521, and FC44097 (n) Receiving Inspection Report Nos. 493 and 25 (o) Pump Characteristics Curves, Drawing Nos. 9107005B and T (p) Periodic Test Procedure Nos. CPL-PT-22.1A, B, and C (q) Auxiliary Feedwater Pump Test Data Sheets dated October 1977 and January 5, 1979 (r) OP N "Disassembly of AFW Pump" dated May 10, 1979 (s) Modification Package N,
"Adding Solenoid Valve to Auxiliary Feedwater Pump System" dated September 11, 1979 (t) H. B. Robinson Plant Organization Chart (u) Drawing G190202 Sheet 3 of 3, Revision 13 "DI Water Header"
-3 8. Purchase Order, Contract and Specifications The Auxiliary Feedwater System at the H. B. Robinson Plant contains three centrifugal pump Two of these pumps are multi-stage and are driven by electric motors supplied by Westinghouse (W). These pumps are designed to deliver 300 gpm. The other pump is a single stage pump and is driven by a steam turbine. This pump is designed to deliver 600 gpm of water to the steam generator All three pumps were purchased by CP&L through their A/E, EBASCO Services, Inc. EBASCO prepared the specifications, obtained bids, selected vendors (Pacific Pump Division of Dresser Industries),
supplied source inspection, witnessed tests, performed final, acceptance inspections prior to shipment, and performed receipt inspections. Purchase Order N was issued on March 29, 1967, EBASCO Specification N was prepared and approved by EBASCO Engineering in August 196 Seven supplements to the specification had been issue These supplements added spare pumps, changed design pressure, added thermocouples, and booster pumps, etc. which were reviewed and approved by the licensee and the original designer Although 10 CFR 50, Appendix B, was not in effect in 1967, the examination of the purchase order, specifications, test data, acceptance criteria and supporting documents showed that the design, fabrication, testing, and inspection were controlled and performed in a quality manne The specification stated that "It is not the intent to completely specify all details of design and construction; nevertheless, the equipment shall in all respects conform to high standards of engineering, design and work manship". The specification also stated that the "equipment shall comply with currently approved applicable specifications and codes of American Standards Association, ASTM and ASME".
The specification contained the technical requirements for the AFW Pumps and accessories. The vendor supplied Contract and Performance Data Sheets which included applicable drawings, test data, material certs, and instruc tion manual The inspector noted that the pump shafts for the AFW Pumps were fabricated from AISI 4140 instead of A276 type 414 stainless steel shafts used on failed charging and safety injection pumps which are subjected to corrosive borated wate (NRC Information Notice No. 80-07)
The inspector noted that the only environmental requirement was that the pumps be "suitable for outdoor use".
Based on the examination of documents and records (which were duplicated and on tapes),
the purchase order, contract and specifications appeared satisfactory and their conditions were me.
Vendor Surveillance and Audits Vendor surveillances and audits were conducted by EBASCO Services, Incorpo rate An examination of records (filed in site vault on tapes) showed that EBASCO performed design review, checked material certifications, performed fabri cation and assembly inspections, and witnessed the testing of the pumps and accessories at the vendor's plan The EBASCO representative visited the vendor's plant approximately every two week Pump test results were submitted to EBASCO Engineering for evaluation prior to acceptance. Docu ments also revealed that nonconforming parts were properly dispositione Problems encountered at the vendor plant were transmitted to EBASCO, CP&L, and W's management for evaluation by EBASCO's representativ The inspector did not find any documentation to confirm that the licensee audited the vendor. Licensee personnel stated that CP&L witnessed the pump performance tests at the vendor's plan.
Receipt, Inspection, Storage and Handling Receipt inspections by EBASCO were performed primarily to determine shipping damage and to ensure that documentation was in orde It was noted that EBASCO inspected the components at the vendor's plant prior to release for shipment. Review of documentation (W letter of 5/29/69) revealed that the Seal Water Booster Pumps had been shipped without prior inspection by EBASCO. W requested that EBASCO inspect at the site. EBASCO QC Report N verified that they performed the inspection as requested by W. No special storage or handling procedures were specified in the original documents reviewed, except for ensuring that all nozzle openings and flanges were to be covered. The licensee presently has approved procedures which address storage, handling, cleanliness, and surveillance activitie.
Installation, Testing, and Acceptance Installation plans, outline dimensions, location, supports, and foundation drawings were available. The pumps and drivers were mounted on an integral bedplate which was bolted to the foundation per Drawing No FC 44097 and 96. Detailed instructions concerning installation were utilized from the vendor instruction manua Records concerning installation, equipment acceptance forms, hydrostatic tests, alignment, electrical check-out data, and acceptance tests are contained on Film Cartridge No and 6 Records of the calibration of torque wrenches and gages were examine Documentation associated with the installation, testing and acceptance was satisfactor Documentation verifying retest of pumps after repair or modification was reviewed and found satisfactor. Maintenance, and Modification Documentation associated with maintenance and modifications performed during 1979 and 1980 were examine Procedures controlling these activities were also reviewe Maintenance activities were recorded on "Trouble Tickets" which required that the trouble be specified, evaluated, and corrective action be approve Materials or spare parts used were approved, work completed was verified,
-5 and retests where applicable were performed. Trouble Ticket No. NM-079 of 7/19/79 specified the disassembly and repair of the overspeed trip mechanism and specified applicable procedures. Periodic Test N CPL-PT-22.1c was performed to verify the performance and to access operational readines Acceptance criteria was specified and was verified during the pump tes Examination of other Periodic Test performed showed that the licensee had verified that all procedures were followed, instruments calibrated, and that the test met acceptance criteri The majority of maintenance activities on these pumps appeared to relate to gland and seal leakage. Also the steam driven pump has been experiencing oil leakage problems for approximately 6 month Corrective action has been to just add oil and not correct the basic proble This was pointed out to management during the exit intervie Management stated that the oil was leaking past the seals when the pump was not running and that they would look further at this proble Other items brought to management's attention was the failure to specify "trouble encountered" in the specified blanks, handwritten instructions not signed, and pump serial number was not on "Trouble Tickets".
Management stated that there was only one steam driven pump; therefore, the serial number was not required and that the handwritten instructions were approved when engineering and QA signed the approval block on the front page of the Trouble Ticke Modification Package N "Replacement of Solenoid Valve" on the Steam Driven Pump Controls was examine This package entailed procedure changes, safety analysis for unreviewed safety questions, technical reviews, procure ment of spare parts, installation and test acceptance, and operating proce dure revisions. Review of the modification package showed that procedures were implemente Due to normal wear, one major overhaul of the steam driven AFW pump was performed on Trouble Ticket N OP-1016 dated May 10, 197 The pumps was rebuilt under the supervision of the vendor's Service Representativ New parts were purchased, inspected, and installed. The pump was retested, and returned to service per TT N OP-137 Examination of documentation revealed that approved procedures were followe The inspector was informed that the licensee has developed a new Trouble Ticket Form which will be used in their "Total Maintenance Management System" progra Interviews with licensee personnel revealed that CP&L submits information to the "Nuclear Plant Reliability Data System" (NPRD)
but do not receive timely feedback. CP&L subscribes to the "Nuclear Operations Maintenance Service" operated by NUS Corporatio The licensee stated that feedback from NUS is timel The inspector did not observe any trend analysis, associated with centrifugal pump problems, being performed by the license.
Documentation and Records The original purchase order, specifications and supplements, fabrication and test data, vendor surveillances, and correspondence between the licensee, EBASCO, Pacific Pump, and Westinghouse had been transferred to duplicate
-6 magnetic tapes. These tapes were filed in the site vault. Most of the documentation examined was on these tape The 1979 and 1980 documents examined were filed in file cabinets located in the site vaul These records had not been put on tapes. Procedures, FSAR's, QA Manuals, and other licensee instructions were readily availabl Documentation and record retention systems were satisfactor. Responsibility, Qualification and Training Responsibilities, qualification and training of personnel associated with the operation, maintenance, modification, and testing of the Auxiliar Feedwater Pumps was examined by document review and personal interview Personnel appeared to be knowledgeable of procedures, qualified for their job functions, vendor instructions manuals had been used for training, procedure changes had been reviewed by operating personnel, and the QA Manual specified position responsibilitie.
Independent Inspection Training Course The inspector attended the licensee's "Orientation and Training Course" which covered Radiation Control, Respiratory Protection, Access Control and Security. This course was four hours long and was attended by licensee employees, contractors, and other personnel requiring access to the site. The courses were presented by video tape and licensee personnel. The training course appeared to thoroughly cover all areas and tdsts were given after each sessio Contaminated Unit 1 Boiler Recirculation Pump The licensee had reported to Region II on June 6, 1980 that a boiler recirculation pump removed from Unit 1 (fossil unit) contained fixed contamination in the pump impeller regio Subsequent to the inspec tor's visit, the licensee had reviewed drawings and plant piping to determine how the pump in Unit 1 could have been contaminated from Unit 2 operation Per request of RII, the inspector reviewed drawings, discussed with licensee personnel, and physically observed the suspected piping are As shown on Drawing N G 190202 Sheet 3 of 3, Revision 13, a 2 inch PVC pipe branches off the PWST piping and goes to Unit The licensee anticipates that radioactive water passed through this 2 inch pipe sometime prior to 1977 where radioactive particulate could have lodged in the pump. As immediate corrective action, the licensee cut out a section of the 2 inch PVC pipe and capped the ends to prevent further transfer of Unit 2 deaerating water to Unit The licensee is preparing an information package to be submitted to RII for their review. This information will be reviewed during a future inspectio (80-10-01)
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